Apparatus and method for loading rolls of web into a chamber

Abstract: An apparatus (10) for loading a roll of web (1) from a stack (3) along a first axis (7) into a chamber (2) along the second axis (8) has a pivotable support member (12) and an engaging means (16) having a head member (18) attached to the support member (12) for engaging a roll along the first axis (7) and guiding the roll (1) into the chamber (4) along the second (8). The support member (12) pivots between a first position in alignment with the stack (3) along the first axis (7) and, a second position in alignment with the chamber opening (4) along the second axis (8). A guide means (22) characterized in that a guide track (24) having first and second elevation positions and predetermined first, second and third stopping means (30), (53), (44) are provided to ensure that the engaging means (16) precisely and repeatedly locates at the desired positions.

Description: The invention relates to an apparatus and method for loading objects into containers. More particularly, the invention concerns an apparatus and method for loading rolls of photographic web from a stack into a chamber within a container for photographic web. Packages or containers that provide photographic web to photofinishing equipment must be periodically loaded with photographic web either by the photofinisher or by the photographic web manufacturer. Conventional apparatus and methods for loading rolls of web, such as photographic paper, into chambers within packages or containers operate in tandem with the manufacturer's web slitter operation. In this operation, once the web is slit it exits the slitter operation having a horizontal orientation. The slit web, while horizontal, is transferred to a "gin pole" or shaft and the "gin pole" is lowered to a height that corresponds to the height of the chamber opening. The slit webs are then pushed from the "gin pole" into the chamber. Thus, existing apparatus is designed to load photographic paper into chambers from the manufacturer's slitter operation and at a photofinisher's location. One shortcoming of the present apparatus for loading packaging chambers, such as the packaging described in US-A-5,383,591, is that the package could not be conveniently loaded by the photofinishers. Instead, because existing apparatus for loading photographic paper is rather cumbersome, the photofinisher has to return the package chamber, once the paper supply is exhausted, to the photographic paper manufacturer for reloading. This practice, of course, results in undesirable photofinishing equipment and processing downtime, excessive shipping cost accruing to both the manufacturer and the photofinisher, and the additional cost to the photofinisher for the convenience of preloaded packages. One prior art apparatus for loading a package container known to the inventors is described in US-A-5,390,872. Generally the apparatus includes a roll support shaft that is preloaded with rolls of web via a hoist and the entire affair is then inserted into the package chamber which interfaces with photofinishing equipment. While this apparatus works well for the top loaded package container described in the application, it would not be suited for a variety of package chamber configurations as the present invention. Moreover, the apparatus described in the application requires considerably more labor support to operate and, it is far more expensive to manufacture. US-A-4,441,662 discloses a device for automatically supplying reels of paper to a utilizer machine, in which a support element for a reel is movable between the output of a reel supplying magazine and an unwinding spindle disposed on the utilizer machine and is provided with an actuator means which is operable to actuate locking means carried by the unwinding spindle, by contact therewith, to lock each reel in succession thereon. The magazine for reserving reels which are disposed with their edges in contact with one another on inclined conveyor belts and stopped by stop devices extends substantially horizontally and in a direction of the reel axis. Beneath the lower end of the magazine and in a position adjacent thereto an elongated box is disposed the axis of which extends substantially horizontally and in a direction perpendicular to the axis of the magazine. Disadvantageously, the device requires additional conveyor belts and stop devices for transporting the reels to the output of the magazine and for stopping them there and requires that the reels have the same diameter. Therefore, a need persists for an apparatus and method for loading rolls of photographic paper into a packaging chamber that is convenient to use, of simple construction, economical and easy to manufacture, compact, and easy to operate by the photofinisher. It is, therefore, an object of the invention to provide an apparatus that overcome the problems of the prior art. Accordingly, for solving of the above problems, in one aspect of the invention, there is provided an apparatus for loading a roll of web as defined in Claim 1. The foregoing as well as other objects, features and advantages of this invention will become more apparent form the appended Figures, wherein like reference numerals denote like elements, and wherein: Figure 1 is a front elevation view, partially broken away, of the apparatus of the invention. Figure 2 is a top plan view showing the lifting head in three positions as the roll of web (a) is being lifted, (b) is guided from the stack and (c) is moved into the chamber. Figure 3 is a front elevation view of the apparatus with the lifting head lowered and positioned in alignment with the container. Figure 4 is a fragmentary, partially sectioned top view of the apparatus along line 4-4 of Fig. 2, showing the lifting head member and the retractable members engaging the roll core. Turning now to the drawings, and more particularly to Figs. 1-3, there is shown the apparatus 10 for loading rolls of web 1 , such as photographic paper, from a stack 3 into a chamber 4 of package 2 , such as the package described in US-A-5,383,591, in accordance with the principals of the invention. The objects or rolls 1 having a central opening 5 are arranged in a vertical stack 3 having a first axis 7 near the apparatus 10 . The stack 3 typically includes several rolls of web 1 with one roll of web 1 atop the other but, it may include only one roll of web 1 . The chamber 4 into which the roll of photographic web 1 is loaded along a spindle 6 defining a second axis 8 transverse to the first axis 7 nominally has a openable end member (not shown) through which the rolls of photographic web 1 enter the chamber 4. The spindle 6 set inside the chamber 4 and accessible through the openable end member provides support for the rolls of photographic web 1 that are loaded therein. Accordingly, broadly defined, the apparatus 10 of the invention comprises a pivotable support member 12 to which is mounted a means 16 for securely engaging the core of a roll 1 , as further described below. In the preferred embodiment, support member 12 is pivotably connected to a fixed frame member 14 attached to the floor or some other suitable stable surface. The frame member 14 provides a reference axis about which the support member 12 pivots between the first axis 7 of the stack 3 of rolls and the second axis 8 of the chamber 4 . Support member 12 is configured to pivot from a first position in alignment with the stack of rolls along the first axis 7 , to a second position in alignment with the chamber 4 along the second axis 8 . A pneumatic lift mechanism 19 is provided for raising the head support member 50 , which operates the head member 18 to clear the stack 3 after engaging a roll of web 1 . A typical lift mechanism preferred by the inventors is one manufactured by D. W. Zimmerman Handling Systems, Madison Heights, Michigan. Those skilled in the art will appreciate that the head support member 50 may also be raised by other means, such as by an electrically operated hoist. The pneumatic lift mechanism 19 , is used to raise and lower the head support member 50 , with and without a roll of web 1 on the head member 18 . The head support member 50 provides a means to support, and connect, the head member 18 to the support member 12 . The engaging means 16 comprises a rotatable extending head member 18 and at least two retractable gripping members 20 mounted in a periphery wall 23 of the head member 18 for engaging the interior wall 9 of the central opening 5 of at least one roll 1 in the stack 3 . Preferably four spaced retractable gripping members 20 are positioned about the head member 18 for securely gripping and delivering the roll of web 1 into the chamber 4 . A core engaging device preferred by the inventors is one manufactured by Tilt-Lock, Inc. of Columbia Hts., Mn. According to Figure 4, the extending head member 18 is inserted into the central opening 5 of the roll 1 and the retractable gripping members 20 , when activated, are lodged into the interior wall 9 , thereby gripping the central opening 9 and, therefore, the roll 1 in a secure manner. Retractable gripping members 20 or "teeth" operate by both gravity and bias springs 51 . When the gripping members 20 are inserted into the interior wall 9 of the central opening 5 (Fig. 4), a light spring pressure is applied to the gripping members 20 that engages them into the interior wall 9 . As the head member 18 is pulled away from the central opening 5 along the first axis 7 , the gripping members 20 penetrate deeper into the interior wall 9 thereby providing secured attachment to the central opening 5 of the roll 1 . Release member 56 enables the operator to disengage the gripping members 20 from the interior wall 9 when unloading the roll 1 onto the spindle 6 in chamber 4 . The head member 18 is preferably substantially cylindrical and has a diameter slightly less than the diameter of the central opening 5 so as to facilitate engagement and securement of the roll 1 . Rotation of the head member 18 is achieved by a gear box 21 . A gear box 21 , preferably one manufactured by DynaTorque Corp. of Muskegon, Mich., is used to rotate the roll web 1 away from the first axis 7 of the vertical stack 3 to a horizontal position, so that it can be inserted onto the fixed spindle 6 along the second axis 8 of the chamber 4 . This operation of rotating the roll of web 1 from a vertical to horizontal position, is preferably performed approximately half way between the first axis 7 of the vertical stack 3 and the second axis 8 of chamber 4 , as shown in Figure 2. It is accomplished by turning the handle 52 attached to the gear box 21 . Those skilled in the art will appreciate that this latter maneuver can also be performed with an electrically driven device. Alternatively, skilled artisans will appreciate that other engaging means 16 would satisfy the requirements of the present invention including a pneumatic expandable spindle, a cam activated device, and a threaded expandable spindle (none illustrated). In Fig. 2, the apparatus 10 is shown with the support member 12 having a roll of web 1 secured to the head member 18 , in the manner described above, lifted away from the stack 3 along the first axis 7 and pivoting toward and into alignment with the chamber 2 along the second axis 8 . In this illustration, the roll 1 is shown being rotated from a horizontal position in the stack 3 to a substantially vertical position as it approaches and aligns with the chamber 4 along the second axis 8 . While not necessary in the preferred embodiment, a guide means 22 comprising a guide track 24 positioned so as to provide continuous riding contact for a follower member 26 fixed to the head support member 50 enables the engaging means 16 to travel between a first elevational position 30 above the stack 3 , to a second elevational position 32 in alignment with the chamber opening. Referring again to Figs. 1 and 2, frame member 14 is shown having first, second and third stopping means 30,53,44 for support member 12 as it pivots between the stack along the first axis 7 and into the chamber 4 along the second axis 8 . First stopping means 30 limits the elevation of the support member 12 when the head member 18 is in alignment with the first axis 7 of the stack 3 . Stopping means 53 fixes the centering position of the head member 18 relative to the central openings 5 of the rolls 1 in stack 3 . Thus, when the support member 12 swings away from the first axis 7 and then returns, it will precisely and repeatedly align with the central openings 5 of the remaining rolls 1 in the stack 3 . Third stopping means 44 provides a means for precisely and repeatedly positioning the support member 12 when the head member 18 is in alignment with the second axis 8 of the chamber 4 . As shown in Fig.1, the head member 18 and gear box 21 are mounted on a slide 54 . This slide 54 allows the operator to accurately position the head member 18 into the central opening 5 of the roll 1 of web 1 in the stack 3 and "lock" its pick-up position at the stack 3 by means of a clamp 55 on a pneumatic cylinder (not shown). The slide 54 also allows the head member 18 to be automatically positioned, by the pneumatic cylinder, at the chamber 4 for loading the roll of web 1 onto the spindle 6 in the chamber 4 . Once this "pick-up" position is established at the stack 3 along the first axis 7 , the remaining rolls of web 1 in the stack 3 can be located automatically by using the pneumatic cylinder. A preferred cylinder is one manufactured by Chicago Cylinder Corp. of Chicago, Ill. This feature compensates for any misalignment of the rolls of web 1 in the stack 3 caused in shipping of the stack 3 to the photofinisher, or its placement in the apparatus 10 . In another embodiment of the invention, a method for loading a roll of web 1 from a stack 3 into a chamber 4 having a spindle 6 for receiving the roll 1 comprising the step of providing apparatus 10 , as described above, having a rotatable extending head member 18 for engaging a roll of web 1 . The head member 18 is centered along the first axis 7 with the central opening 5 of the top most roll 1 in the stack 3 . After centering the head member 18 , it is lowered into the central opening 5 of the top most roll 1 in the stack 3 . An engaging means 16 is then activated that securely engages the interior wall 9 of the central opening 5 of roll 1 thereby locking the roll 1 onto the head member 18 . Following the roll locking step, the head member 18 with a roll of web 1 locked thereon is raised first upwardly along the first axis 7 away from the stack 3 with the aid of lift mechanism 19 . The head member 18 with the roll 1 locked thereon is then guided into alignment with the chamber 4 along the second axis 8 . Once aligned with the second axis 8 of the chamber 4 , the roll 1 is then inserted therein by first releasing the roll of web 1 from the head member 18 and then pushing the roll 1 into sliding contact with the spindle 6 inside the chamber 4 . After the roll 1 is loaded onto the spindle 6 , the head member 18 is moved away along the second axis 9 of the chamber 4 and then back into position to engage another roll 1 in the stack 3 along the first axis 7 . Accordingly, an important advantage of the present invention is that it provides an apparatus 10 and method for loading rolls of photographic web 1 into a chamber 4 that is convenient to use, of simple construction, economical and easy to manufacture, compact and easily operated by the photofinisher.

Claims: Apparatus (l0) for loading an object (1) including a central opening (5 with an interior wall (9), comprising a fixed frame member (14) having a reference axis; a stack (3) containing said object (1) being spaced from said frame (14), said stack having a first axis (7); said apparatus (10) being characterized by: a chamber (4) arranged about the frame (14) for receiving said object (1), said chamber having a second axis (8) transverse to said first axis (7) of said stack (3); a support member (12) pivotably mounted to said frame member (14) for rotation about said reference axis between a first elevational position above the stack (3), and a second elevational position in alignment with the chamber (4) opening; a head support member (50) mounted to said support member (12), said head support member (50) having a head member (18) mounted thereon; means for guiding (22) said head support member (50), said means for guiding (22) comprising a guide track (24), said guide track (24) defining a first elevational position along said first axis (7) and a second elevational position along said second axis (8); engaging means (16) rotatably mounted to said head member (18) for firmly engaging the object (1) along said first axis (7) and delivering the object (1) along said second axis (8) into the chamber (4); and means (19) mounted to said support member (12) for raising and lowering said head member (18) between said first and second positions. The apparatus (10) recited in claim 1 further characterized by a first stopping means (30) provided for limiting the elevation of the support member (12) when the head member (18) is in alignment with the first axis (7) of the stack (3). The apparatus (10) recited in claim 2 further characterized by a second stopping means (53) provided for precisely and repeatedly locating said head member (18) relative to said central opening (5) of said object (1). The apparatus (10) recited in claim 3 further characterized by a third stopping means (44) provided for precisely and repeatedly locating said support member (12) when the head member (18) is in alignment with the in said second axis (8) of the chamber (4). The apparatus (10) recited in Claim l, further characterized by a slide (54) mounted to said head support member (5), said engaging means (16) being supported by said slide (54).

Inventors: FAIRBROTHER MATTHEW D, SALSBURG FREDRIC S, FAIRBROTHER, MATTHEW D., SALSBURG, FREDRIC S., Fairbrother, Matthew D., c/o Eastman Kodak Co., Salsburg, Fredric S., c/o Eastman Kodak Co.
Applicants: EASTMAN KODAK CO, EASTMAN KODAK COMPANY
Application year: 1994
Main classification: B65H19
IPC codes: G03C3, B65G59, B65H19, B65G57, B65G60, G03B27